Mattress with a Membrane Spring Array

ABSTRACT

Various embodiments of this invention disclose a mattress with an internal spring array, and the springs of the internal spring array are mounted back to back on a membrane. The mattress also has two cover layers and a frame layer that enclose the internal spring array. The springs of the spring array have support plates connected to a base section via a spring arm.

FIELD OF INVENTION

This invention generally relates to mattresses. Moreover, it pertainsspecifically to a mattress with an internal spring array, and thesprings of the internal spring array are mounted back to back on amembrane. The mattress also has two cover layers and a frame layer thatenclose the internal spring array. The springs of the spring array havesupport plates connected to a base section via a spring arm. This typeof spring is known in the art as a Belleville spring.

BACKGROUND

For centuries, people have been sleeping on mattresses to get a morecomfortable rest, in order to be elevated off of the floor, and to gainprotection from the elements. Several challenges face designers ofmattresses including how to provide a reasonably priced high qualitymattress, how to provide sufficient ergonomic support, how to reduce theamount of the sleeper's perspiration that is absorbed and retained bythe mattress, and how to make the springs of the mattress last longerand provide more comfort. Two common types of mattresses are the metalspring mattress and the foam mattress. Although both the metal springmattress and the foam mattress provide a more comfortable rest thansleeping on the floor, neither adequately reduces the absorption andretention of moisture and perspiration by the mattress. Moisture andperspiration absorption and retention is bad because dust mites thriveon the moisture and perspiration retained by the mattress. Excessivedust mite dander and waste causes an allergic response in many people.Additionally, metal spring mattresses fatigue from use, start to sag,and become increasingly less comfortable. Metal spring mattresses thatare inexpensive do not sufficiently protect the sleeper from pressurepoints caused by the metal springs. Metal spring mattresses are veryheavy and very difficult to move or even flip over. Metal springmattress cause electromagnetic fields, which can interfere with sleep.There is a need in the art for a mattress that is light, free of metal,ergonomic, comfortable, and allows proper ventilation to reduce theamount of perspiration and moisture that is absorbed and retained by themattress.

In the field of Belleville springs, some springs have been developedthat function as a support system for separate cushions. One suchBelleville spring is disclosed by U.S. Pat. No. 6,826,791 to Fromme(hereinafter “Fromme 1”), which discloses a spring element forsupporting a seat cushion or a mattress. The Fromme 1 spring elementsconnect to a rigid platform in an array that supports a separate cushionon which a user sits or sleeps. Although Fromme 1 discloses an optimaltype of spring, it fails to disclose attaching these springs back toback on a single contiguous and flexible membrane and inserting theresulting internal spring membrane array into the core of a double-sidedmattress. In fact, Fromme 1 specifically recites that the springs, whenarrayed on a rigid platform, act similar to a box spring, and not as amattress core. This is a fundamental difference

Another Belleville spring cushion support system is disclosed by U.S.Pat. No. 5,787,533 to Fromme (hereinafter “Fromme 2”), which discloses acushioning support system for a mattress comprising a plurality ofsprings forming a grid structure. Fromme 2 specifically discloses andclaims a box spring system that supports a foam chair cushion or amattress. Although Fromme 2 discloses an optimal type of spring, itfails to disclose attaching these springs back to back on a singlecontiguous and flexible membrane and inserting the resulting internalspring membrane array into the core of a double-sided mattress. In fact,Fromme 2 specifically recites that the springs, when arrayed on a rigidplatform, act similar to a box spring, and not as a mattress core.

Another Belleville spring cushion support system is disclosed by U.S.Pat. No. 6,477,727 to Fromme (hereinafter “Fromme 3”), which disclosessupport structure for a cushion or a mattress comprised of intersectingsupport structure elements (under-crosses or grid sections) with bearing(spring) elements connected on top. See FIG. 7 a and Col. 7 lines 29-31.Although Fromme 3 discloses an optimal type of spring, it fails todisclose attaching these springs back to back on a single contiguous andflexible membrane and inserting that internal spring membrane array intothe core of a double-sided mattress.

In the area of mattress ventilation systems and structures, severalsystems and structures have been developed that allow ventilation in aneffort to avoid moisture absorption and retention. One such mattressventilation system is disclosed by U.S. Pat. No. 6,182,315 to Lee, whichdiscloses a three layer nylon and steel fiber mesh structure that isplaced on top of a cushion or mattress. Although Lee's structure doespromote ventilation, it fails to disclose a mattress with Bellevillesprings attached back to back on a single contiguous membrane andinserting that internal spring membrane array into the core of adouble-sided mattress. Further, Lee's ventilation structure is moreconcerned with allowing perspiration to evaporate from the user's body,rather than allowing perspiration and moisture to ventilate out of themattress itself.

In the area of internal cushion layers adjoining a spring layer inmattresses, numerous mattresses feature cushions that enclose a springcore. One such mattress is disclosed by U.S. Pat. No. 6,721,982 toFreeman, which discloses a quilted internal cushion directly adjacent toa spring array core of a mattress. Although Freeman recites a cushionlayer or layers that enclose a spring core of a mattress, it fails todisclose a mattress with a core comprised of Belleville springs attachedback to back on a single contiguous membrane.

In the field of two spring arrays making up the core of a mattress,several mattresses feature mattresses cores with dual spring arrays. Onesuch mattress is disclosed by U.S. Pat. No. 5,401,007 to Dabney et al.(hereinafter “Dabney 1”), which discloses a wire spring mattress corewherein two separate spring arrays that snap fit together in a front tofront connection. The Dabney 1 mattress core specifically recites thateach of the spring arrays attaches to a separate grid support. As such,the Dabney 1 mattress core has two separate grid supports and thesprings are connected in a face to face manner. Although Dabney 1discloses a double-sided mattress core with two spring arrays, it doesnot disclose a non-wire Belleville spring, or springs that are attachedback to back on a single grid support. Further, Dabney 1 recites thatthe base of the springs are adjacent to the enclosing cushioning layers.Thus, Dabney 1 does not disclose a mattress core wherein the distal endof the springs are adjacent to the enclosing cushioning layers.

Another type of dual spring array mattress cores is disclosed by U.S.Pat. No. 5,395,097 to Dabney et al. (hereinafter “Dabney 2”), whichdiscloses a wire spring mattress core wherein two separate spring arraysnestably fit together in a distal end to distal end connection. TheDabney 2 mattress core specifically recites that each of the springarrays attaches to a separate grid support. As such, the Dabney 2mattress core has two separate grid supports and the distal end of thesprings contact or attach nestably to the base end of opposite gridsupport. Although Dabney 2 discloses a double-sided mattress core withtwo spring arrays, it does not disclose a non-wire Belleville spring, orsprings that are attached back to back on a single grid support. Thereversed orientation of Dabney I or Dabney II is integral to thoseinventions and it would not be an obvious improvement merely to reversethe orientation, because to do so, the entire structure of the mattresswould be affected and changed thereby.

In the area of non-wire springs, numerous types have been developed thatallow mattresses to be made with non-wire springs. One such non-wirespring is disclosed by U.S. Pat. No. 6,113,082 to Fujino, whichdiscloses a non-wire spring that is shaped similar to traditional wiresprings for mattresses. Fujino recites a resin or plastic spring whereinthe springs are arrayed parallel between two grid supports. AlthoughFujino discloses a non-wire spring array inserted into the core of adouble-sided mattress, it fails to disclose a Belleville spring, orsprings that are attached back to back on a single contiguous membrane.

Thus, there remains a long-felt need in the art for an inexpensive,ergonomic, and comfortable mattress with proper ventilation to reducethe amount of perspiration and moisture that is retained by themattress. It is also clear that there is a need in the art for a systemof quickly and inexpensively assembling an internal spring array for amattress.

SUMMARY OF THE INVENTION

To minimize the limitations in the prior art, and to minimize otherlimitations that will become apparent upon reading and understanding thepresent specification, the present invention discloses an internalspring array of a mattress wherein the springs are mounted back to backon a membrane, a method for making an internal spring array of amattress, and a mattress with two cover layers that enclose an internalspring array wherein the springs are mounted back to back on a membraneand this spring array is surrounded by a frame layer.

One embodiment of this invention is a mattress comprising: a top coverlayer; a bottom cover layer; a membrane spring array comprising aplurality of springs, and a membrane with a plurality of holes. Theplurality of springs are mounted on opposite sides of the membrane. Theplurality of springs are plastic and comprised of a support plate, aplurality of spring arms, and a base. The plurality of springs showvarying spring flexibility depending on where they are located on themembrane. The membrane has a plurality of ventilation apertures. Themattress further comprises a frame layer that encloses or surrounds thespring array. The mattress also has a removable mattress cover. Themattress is divided into a plurality of recumbence areas and theserecumbence areas exhibit differing spring flexibility. The recumbenceareas are separated by flanges so that they can provide independentsupport and flex characteristics. The plurality of recumbence areas aredivided further into a plurality of subdivisions and these subdivisionsalso exhibit varying spring flexibility.

Another embodiment of the invention is a mattress comprising a top coverlayer, a bottom cover layer, and a membrane spring array comprising aplurality of spring portions and a membrane portion. The plurality ofspring portions are contiguous with and permanently attached to themembrane portion. The membrane spring array is plastic. The plurality ofsprings are comprised of a support plate, a plurality of spring arms,and a base. The plurality of springs show varying spring flexibilitydepending on where they are located on said membrane. The membrane has aplurality of ventilation apertures. The mattress further comprises aframe layer that encloses a plurality of sides of said spring array, anda removable mattress cover. The mattress is divided into a plurality ofrecumbence areas, and the plurality of recumbence areas exhibitdiffering spring flexibility. The plurality of recumbence areas areseparated by flanges so that said plurality of recumbence areas provideindependent support and flex characteristics. The plurality ofrecumbence areas are divided into a plurality of subdivisions, and theplurality of subdivisions exhibit varying spring flexibility.

An object of the present invention is to provide a light weight,ergonomic, and comfortable mattress that will overcome the deficienciesof the prior art.

Another object of the present invention is to provide a mattress thatallows proper ventilation to prevent the absorption and retention ofmoisture and perspiration.

Another object of the present invention is to provide a mattress that isnot made with wire or metal springs that can cause: 1) painful pressurepoints that prevent muscles from fully relaxing; 2) electromagneticfields; and 3) the mattress to be excessively heavy.

Another object of the present invention is to provide a system ofquickly and inexpensively assembling an internal spring array for amattress.

Another object of the present invention is to provide a light weight,ergonomic, and comfortable internal spring array for a mattress thatwill overcome the deficiencies of the prior art.

The present invention is a significant improvement over the usual metalspring mattress. Because the spring core of a usual metal springmattress cannot distribute the load of a reclining person to the bestadvantage, the metal springs are connected to two spring supports (onetop support and one bottom support) in the form of rigid or flexiblelatticework. Instead of two spring support latticeworks, an embodimentof the present invention simply connects two Belleville springs togetherat their bases with each spring mounted on opposing sides of a singlecontiguous membrane. After being mounted on the membrane, the springsupport plates are directed away from the spring base. The supportplates then act as a defacto support latticework when they are in flushcontact with the cover layer to which they are adjacent. Importantly,the spring support plates, unlike traditional metal springs, need noadditional bracing beyond what is provided by the other springcomponents and the membrane. The membrane is perforated with ventilationapertures, which both reduce the weight of the membrane and allow forbeneficial ventilation. When the spring array of the present inventionis inserted into the mattress cavity, the cavity is still relativelyhollow and thus allows for beneficial ventilation.

To facilitate ease of construction, limit movement of the sets ofsprings across the surface of the membrane, and limit the sets ofsprings from rotating perpendicularly to the membrane once they aremounted through it, a set of one or more mounting pins withcorresponding pin receivers are either part of the base of the spring orare used as separate parts to hold the springs together at the desiredlocation on the membrane. These pins mount through one or more holes inthe membrane that serve to dictate the location of the sets of springs.The preferred embodiment is to have two mounting holes in the surface ofthe membrane for each dual spring mounting location and a pin and areceiver on the base of each spring projecting outward from the bottomsurface of the spring base. Each spring in a set of springs preferablyhas one mounting pin inserted through one of the two holes in themembrane and a receiver hole located concentrically to the other hole inthe membrane. The mounting pins from each of the pins preferably insertthrough the membrane and into the receiver hole on the opposing springin its set. The two pins penetrating through the membrane will act tolimit the rotation of the spring set. In other embodiments of theinvention the springs that are mounted opposite each other may bedivided between male and female springs. The male spring has twomounting pins and the female spring has two receiving holes.

Other features and advantages are inherent in the mattress claimed anddisclosed will become apparent to those skilled in the art from thefollowing detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a detailed illustration of a top view of one embodiment of aspring.

FIG. 2 is a detailed illustration of a side view of one embodiment of aspring.

FIG. 3 is a detailed illustration of a side view of two springs about tobe mounted on the membrane.

FIG. 4 is a detailed illustration of a side view of two springs mountedon the membrane.

FIG. 5 is an illustration of a top view of one corner of one embodimentof the membrane without springs attached.

FIG. 6 is an illustration of a cutaway side view of the membrane to showseveral bisected membrane holes and ventilation apertures.

FIG. 7 a is an illustration of a top view of several sections of oneembodiment of the internal spring array.

FIG. 7 b is an illustration of a cutaway top view of one section of oneembodiment of the internal spring array.

FIG. 8 a is an illustration of a cutaway side view of one section of oneembodiment of the mattress.

FIG. 8 b is an illustration of a cutaway side view of one section of oneembodiment of the mattress to show the flanges.

FIG. 9 is a perspective illustration of an exploded view of oneembodiment of the mattress.

FIG. 10 is a perspective illustration of a cut-away of one embodiment ofthe mattress.

DETAILED DESCRIPTIONS OF THE DRAWINGS

In the following detailed description of the preferred embodiment,reference is made to the accompanying drawings that form a part hereof,and in which is shown by way of illustration a specific embodiment inwhich the invention may be practiced. It is to be understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from the scope of the present invention.

In the following detailed description of various embodiments of theinvention, numerous specific details are set forth in order to provide athorough understanding of various aspects of one or more embodiments ofthe invention. However, one or more embodiments of the invention may bepracticed without these specific details. In other instances, well-knownmethods, procedures, and/or components have not been described in detailso as not to unnecessarily obscure aspects of embodiments of theinvention.

In the following description, certain terminology is used to describecertain features of one or more embodiments of the invention. Forinstance “plastic” refers to any natural or synthetic polymer resin suchas cellulose, polyethylene or polystyrene. “Foam” refers to any natural,or synthetic soft and supportive padding such as polyurethane foam, foamrubber, or viscoelastic memory foam. Foam can also be made fromrenewable resources, such as soy, corn, or castor oil.

FIG. 1 is a detailed illustration of a top view of one embodiment of aspring. FIG. 1 shows spring 100 is comprised of a support plate 102,spring arms 103, and a base 104. Preferably, spring 100 will have fourspring arms 103, but spring 100 can have a range of spring arms 103,from as few as two to as many as one hundred. Spring 100 functionssimilar to that of a Belleville type spring that is known to theindustry. When compressed this spring 100 annularly spreads, meaning thespring arms 103 deform downward and outward, and the support plate 102deforms outward. As shown in FIG. 2, the support plate 102 hasconnection bands 105 that are between the areas where the support plate102 and the spring arms 103 connect. These connection bands 105 act tolimit the deformation of the spring arms 103 by controlling the annularspread of support plate 102. The annular spread can be furthercontrolled by attaching a restraining cross clip to the connection bands109. This restraining cross clip limits how far apart the connectionbands 109 can pull away from each other, and thus makes the mattressfirmer. Spring 100, via support plate 102, is preferably in directcontact with a cover layer, top or bottom (as detailed in FIGS. 9 and 10below). Spring 100 preferably has both a mounting pin 110 and receivinghole 120. However, spring 100 can have multiple mounting pins 110 andreceiving holes 120 without departing from the scope of the presentinvention. Additionally, spring 100 need not have both a receiving holeand a mounting pin, so long as one or the other is present. Spring 100can be made so that it is either a male spring with mounting pins, butno receiving holes, or a female spring with receiving holes, but nomounting pins. If springs are given a male/female configuration, a malespring would be mounted opposite a female spring.

FIG. 2 is a detailed illustration of a side view of one embodiment of aspring. FIG. 3 shows spring 200 is comprised of a support plate 202,spring arms 203, and a base 204. Preferably spring 200 has a mountingpin 210 extending perpendicularly away from base 204. Spring 200 ispreferably 13 centimeters in length and width and 10 centimeters inheight when uncompressed. However, spring array 200 can range from 3centimeters in length, width, and height, to 60 centimeters in length,width, and height.

FIG. 3 is a detailed illustration of a side view of two springs about tobe mounted on the membrane. FIG. 3 shows two springs 300 and 301 aboutto be mounted back to back on membrane 350. Preferably membrane 350 hastwo membrane holes 360 and 361, at each spring mounting location, toallow the mounting pins 310 and 311 of springs 300 and 301 to pierce themembrane. Preferably the mounting pins 310 and 311 also pierce thespring receiving holes 320 and 321. The mounting pins act as insertionor friction snap closures to keep the two springs 300 and 301 mountedsecurely back to back on the membrane. The pins also act to limit thesets of springs from twisting or rotating perpendicularly along themembrane once they are mounted. Although the mounting pins arepreferably an attached extension of the springs 300 and 301, they can bea plurality of separate parts that are individually pushed into thespring receiving holes 320 and 321 and membrane holes 360 and 361 tosecurely mount the springs 300 and 301 onto the membrane 350. Thepreferred method of mounting springs to the membrane 350 creates aspring array that is easy, fast, and inexpensive to assemble. The springmounting pins 310 and 311 easily fit into the opposing spring receivingholes 320 and 321 and the membrane holes 360 and 361 in a one-direction,compressive assembly motion. This allows the spring array of a mattressto be accomplished by laying a series of springs, bottom up, on a tablewith their mounting pins projecting upward. A pre-hole punched membranecan easily be laid across the series of springs and the spring mountingpins will insert through the membrane holes and mount securely. Theopposite side springs can then be mounted in a similar manner. Theopposite side spring mounting pins are inserted through the remainingmounting hole at each spring mounting location.

FIG. 4 is a detailed illustration of a side view of two springs mountedon the membrane. FIG. 4 shows two springs 400 and 401 (which are thesame as the two springs 300 and 301 shown in FIG. 3) mounted back toback on membrane 450. As shown in FIG. 4, the mounting pin 411 of spring401 has pierced the membrane 450 and receiving hole of spring 400.Conversely, the mounting pin 410 of spring 400 has pierced the membrane450 and receiving hole of spring 401. FIG. 4 shows springs 400 and 401are securely mounted opposite each other on membrane 450 and areprevented from twisting or rotating perpendicularly along the plane ofthe membrane 450.

FIG. 5 is an illustration of a top view of one corner of one embodimentof the membrane. FIG. 5 shows the entire top side of membrane 550.Preferably, membrane 550 has a plurality of membrane holes 560 thatperforate the membrane in sets of two. These sets of membrane holes formthe site of the spring mounting locations. FIG. 5 also details thatmembrane 550 has ventilation apertures 570 that allow for beneficialventilation in the mattress core and reduced weight of the membrane 550.Preferably the ventilation apertures 570 are placed in a logical andsymmetrical pattern amongst the membrane holes 560. However, theventilation apertures 570 can be placed in a random manner. Ventilationapertures 570 preferably do not intersect the membrane holes 560 and arelocated far enough away from the membrane holes 560 such that membraneholes 560 are not weakened structurally. As FIG. 5 shows, membrane 550preferably has one ventilation aperture 570 for every four sets ofmembrane holes 560. However, the ratio between membrane holes 560 andventilation apertures 570 can range from having more ventilationapertures 570 then membrane holes 560, or the membrane holes 560 can outnumber ventilation apertures 570 by as great as fifty to one. As shownin FIG. 5, the ventilation apertures 570 are preferably larger than themembrane holes 560, however, ventilation apertures 570 can be smallerthan, or the same size as, the membrane holes 560 without deviating fromthe scope of the invention. Membrane 550 is preferably made from a thinyet durable layer of plastic, but can be made from any natural orsynthetic material such as: metal; metal alloy; wood or other fibrousplant product such as hemp, paper, or cardboard; composite materialssuch as graphite, fiberglass, boron, or Kevlar®; admixtures of plasticresins combined with metal, metal alloy, wood or other fibrous plantproduct, or composite materials; reinforced fabric; or any combinationof these materials, without departing from the scope of the presentinvention. Preferably the membrane is flexible, but should resistcollapsing across its plane. Preferably membrane 550 is a single layerof contiguous material, but can be made from a plurality of layers, aplurality of conjoined membranes, or both.

FIG. 6 is an illustration of a cutaway side view of the membrane anddetails several bisected membrane holes and ventilation apertures. Asshown in FIG. 6, membrane 650 the membrane holes 660 and the ventilationapertures 670 preferably completely perforate the membrane 650. However,it is possible to mount the springs to a membrane whose membrane holesdo not completely perforate the membrane without deviating from thescope of the invention.

FIG. 7 a is an illustration of a top view of several sections of oneembodiment of the internal spring array to show the varying springflexibility. FIG. 7 a details the varying spring flexibility dependingon where the springs are located on the membrane. As shown in FIG. 7 a,mattress 750 preferably has a pattern of varying spring flexibility thatis laid out in a symmetrical mirror image. This allows either end of thespring array 785 to act as the head end. FIG. 7 a shows that springarray 785 has a head end at frame layer 783, and a foot end at framelayer 784. The user's head would rest on frame layer 783 and his or hershoulders would rest on the springs in area 707, which are softer (moreflexible) than springs in area 708, which would be beneath the user'sback. The springs in area 709 are firmer springs and would support theuser's torso. The rest of the spring array 785, which would support thelegs, is a mirror image of the head end of the mattress. This way theuser can lie with his or her head at either end of the mattress and getthe same ergonomic support for his or her back, shoulders and torso. Thesprings of the spring array can be made stiffer in a variety of waysincluding, but not limited to, using a less flexible plastic, increasingthe density or rigidity of the plastic, by adding restraining crossclips, or by manufacturing a spring with thicker portions.

FIG. 7 b is an illustration of a cutaway top view of one section of oneembodiment of the internal spring array. As shown in FIG. 7 b, thesprings 700 are mounted on the top side of the membrane of internalspring array 785. The springs 700 are preferably arrayed, in anequidistant and symmetrical grid-like pattern, but any equidistantmounted pattern can be used depending on the shape and symmetry of thesprings. FIG. 7 b also shows how the internal spring array 785 ispreferably the core of a mattress. As shown in FIG. 7 b, frame layer781, 782, 783, and 784 enclose internal spring array 785. However, theframe layer can also enclose only two or three sides without deviatingfrom the present invention.

FIG. 8 a is an illustration of a cutaway side view of one section of oneembodiment of the mattress. As shown in FIG. 8 a, internal spring array885 is the core of mattress 890. Internal spring array 885 preferablyhas springs 800 mounted linearly in an equidistant manner on the sameside of membrane 850, and mounted in a back to back manner on oppositeside of membrane 850. As shown in FIG. 8 a, internal spring array 885 isenclosed by side frame layer 881 and 882 and by top layer 891 and bottomlayer 892 (discussed in FIGS. 9 and 10 below).

FIG. 8 b is an illustration of a cutaway side view of one section of oneembodiment of the mattress and details the flanges. Mattress 890, asshown in FIG. 5, can have flanges 895, which divide mattress 890 intoseparate recumbence areas 896, 897, and 898. The mattress 890 can bedivided latitudinally, longitudinally, or both. The flanges 895 arepreferably identical in characteristic and make to frame layer 880, butthe flanges may be more rigid (or thicker) or more flexible (or thinner)than frame layer 880 depending on how much support is desired at thatlocation in mattress 890. The separate recumbence areas 896, 897, and898, preferably provide independent support and flex characteristicsbecause they are divided by the supportive flanges 895, and because thespring arrays 885 inserted into separate recumbence areas 896, 897, and898 may have springs that differ in their spring flexibility. Thus,recumbence area under the shoulders may be less rigid and the recumbencearea under the torso may be more firm. Each of these recumbence areascan be further sub-divided so that specific portions of the recumbencearea is stiffer or more giving than the other subdivisions of thatrecumbence area. Of course, FIG. 8 b shows just one embodiment of theinvention, and there can be more than three recumbence areas, or fewerthan three recumbence areas as described.

FIG. 9 is a perspective illustration of an exploded view of oneembodiment of the mattress. Mattress 990 in FIG. 9 is shown with a topcover layer 991, a bottom cover layer 992, side frame layer pieces 981and 982, head and foot frame layer pieces 983 and 984, and internalspring array 985. When the mattresses' parts are fitted together thesprings of internal spring array 985 are preferably in flush contactwith both top layer 991 and bottom layer 992. When a person lies onmattress 990, pressure is applied to either or both cover layers, andthe pressure is transmitted to the springs of the internal spring array985. The internal spring array 985 responds to the pressure and supportsin an ergonomic fashion the body of the person lying down. The top layer991 and the bottom layer 992, as shown in FIG. 9, are preferably eachmade of a single layer of foam, but they can be made of any natural orsynthetic soft padded or quilted material such cotton, nylon, horsehair, feathers, down, wool, or any combination of these materials.Additionally, top layer 991 and the bottom layer 992 can be made out ofany number of layers of foam or padding, from two to two million, andwhose thickness can be from .01 centimeters to 100 centimeters. As shownin FIG. 9, the framing layer pieces 981, 982, 983, and 984, preferablyenclose internal spring array 985 on all sides. However, the frame layercan also enclose only two or three sides without deviating from thepresent invention. The framing layer provides support on the edges ofmattress and holds the internal spring array 985 in the center ofmattress 990. The frame layer pieces 981, 982, 983, and 984, preferablyare made from foam and are the same height as the spring array, but theycan be made out of padded plastic or other soft yet rigid materials orcombination of materials that can act to stabilize the edges of mattress990. Mattress 990 is preferably a standard size mattress, such as atwin, double, queen, king, or California king, but it can be customizedto form any size so as to fit any space such as an infant cradle, crib,antique bed, recreational vehicle, boat or yacht, lawn or pool loungingchair, or an entire floor of a room of a home. Mattress 990 can be madewith a weather resistant mattress cover that would allow mattress 990 tobe suitable for outdoor use.

FIG. 9 also shows that internal spring array 985 can be made from aplurality of springs that are contiguous with, and permanently attachedto, the membrane. This type of spring array is preferably manufacturedvia an injection mold process, but can be manufactured using any meansthat creates an internal spring array wherein the springs are contiguouswith and permanently attached to the membrane. The permanently attachedsprings of this embodiment of an internal spring array preferablyexhibit the same function, form, and spring characteristics as thosesprings described in paragraphs [0038] to [0041] above. The membrane ofthis embodiment of an internal spring array preferably exhibits the samefunction, form, and characteristics as that membrane described inparagraph [0042] above.

FIG. 10 is a perspective illustration of a cut-away view of oneembodiment the mattress. Mattress 990 in FIG. 10 is shown with a topcover layer 991, a bottom cover layer 992, side frame layer pieces 981and 982, and head and foot frame layer pieces 983 and 984. Insidemattress 990 is a cavity that contains an internal spring array (asdetailed in FIG. 9 above).

In summary, the present invention is an internal spring array of amattress wherein the springs are mounted back to back on a membrane, amethod for making an internal spring array of a mattress, and a mattresswith two cover layers that enclose an internal spring array wherein thesprings are mounted back to back on a membrane and this spring array issurrounded by a frame layer.

The foregoing description of the preferred embodiment of the inventionhas been presented for the purposes of illustration and description.While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe above detailed description, which shows and describes illustrativeembodiments of the invention. As will be realized, the invention iscapable of modifications in various obvious aspects, all withoutdeparting from the spirit and scope of the present invention.Accordingly, the detailed description is to be regarded as illustrativein nature and not restrictive. Also, although not explicitly recited,one or more embodiments of the invention may be practiced in combinationor conjunction with one another. Furthermore, the reference ornon-reference to a particular embodiment of the invention shall not beinterpreted to limit the scope the invention. It is intended that thescope of the invention not be limited by this detailed description, butby the claims and the equivalents to the claims that are appendedhereto.

1. A mattress comprising: a top cover layer; a bottom cover layer; and amembrane spring array comprising a plurality of springs and a membranewith a plurality of holes; wherein said plurality of springs are mountedon opposite sides of said membrane; wherein said plurality of springsare plastic; and wherein said plurality of springs are comprised of asupport plate, a plurality of spring arms, and a base.
 2. The mattressof claim 1, wherein said plurality of springs show varying springflexibility depending on where they are located on said membrane.
 3. Themattress of claim 2, wherein said membrane has a plurality ofventilation apertures.
 4. The mattress of claim 3, further comprising: aframe layer that encloses a plurality of sides of said spring array; anda removable mattress cover.
 5. The mattress of claim 4, wherein saidmattress is divided into a plurality of recumbence areas, said pluralityof recumbence areas exhibit differing spring flexibility.
 6. Themattress of claim 5, wherein said plurality of recumbence areas areseparated by flanges so that said plurality of recumbence areas provideindependent support and flex characteristics.
 7. The mattress of claim6, wherein said plurality of recumbence areas are divided into aplurality of subdivisions, and said plurality of subdivisions exhibitvarying spring flexibility.
 8. A mattress comprising: a top cover layer;a bottom cover layer; a membrane spring array comprising a plurality ofsprings and a membrane with a plurality of holes; a frame layer thatencloses a plurality of sides of said spring array; and a removablemattress cover; wherein said plurality of springs are mounted onopposite sides of said membrane; wherein said plurality of springs areplastic; wherein said plurality of springs are comprised of a supportplate, a plurality of spring arms, and a base; wherein said plurality ofsprings show varying spring flexibility depending on where they arelocated on said membrane; wherein said membrane has a plurality ofventilation apertures; wherein said mattress is divided into a pluralityof recumbence areas, said plurality of recumbence areas exhibitdiffering spring flexibility; wherein said plurality of recumbence areasare separated by flanges so that said plurality of recumbence areasprovide independent support and flex characteristics; and wherein saidplurality of recumbence areas are divided into a plurality ofsubdivisions, and said plurality of subdivisions exhibit varying springflexibility.
 9. A mattress comprising: a top cover layer; a bottom coverlayer; and a membrane spring array comprising a plurality of springportions and a membrane portion; wherein said plurality of springportions are contiguous with and permanently attached to said membraneportion; wherein said membrane spring array is plastic; and wherein saidplurality of spring portions are comprised of a support plate, aplurality of spring arms, and a base.
 10. The mattress of claim 9,wherein said plurality of spring portions show varying springflexibility depending on where they are located on said membraneportion.
 11. The mattress of claim 10, wherein said membrane portion hasa plurality of ventilation apertures.
 12. The mattress of claim 11,further comprising: a frame layer that encloses a plurality of sides ofsaid spring array; and a removable mattress cover.
 13. The mattress ofclaim 12, wherein said mattress is divided into a plurality ofrecumbence areas, and said plurality of recumbence areas exhibitdiffering spring flexibility.
 14. The mattress of claim 13, wherein saidplurality of recumbence areas are separated by flanges so that saidplurality of recumbence areas provide independent support and flexcharacteristics.
 15. The mattress of claim 14, wherein said plurality ofrecumbence areas are divided into a plurality of subdivisions, and saidplurality of subdivisions exhibit varying spring flexibility.
 16. Amattress comprising: a top cover layer; a bottom cover layer; a membranespring array comprising a plurality of spring portions and a membraneportion; a frame layer that encloses a plurality of sides of said springarray; and a removable mattress cover; wherein said plurality of springportions are contiguous with and permanently attached to said membraneportion; wherein said membrane spring array is plastic; and wherein saidplurality of spring portions are comprised of a support plate, aplurality of spring arms, and a base; wherein said plurality of springportions show varying spring flexibility depending on where they arelocated on said membrane portion; wherein said membrane portion has aplurality of ventilation apertures; wherein said mattress is dividedinto a plurality of recumbence areas, and said plurality of recumbenceareas exhibit differing spring flexibility; wherein said plurality ofrecumbence areas are separated by flanges so that said plurality ofrecumbence areas provide independent support and flex characteristics;and wherein said plurality of recumbence areas are divided into aplurality of subdivisions, and said plurality of subdivisions exhibitvarying spring flexibility.